Solar panel array

ABSTRACT

A solar panel array is provided. The solar panel array includes a plurality of support structures. The support structures are secured to a surface and may support panels, such as solar panels. A row spacer bar may attach a pair of support structures together. A clamp may clamp the panels to the row spacer bar.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation-in-part of application number 14/053,374, filed Oct. 14, 2013.

BACKGROUND OF THE INVENTION

The present invention relates to a solar panel array and, more particularly, to an improved clamping system for clamping solar modules to panel support structures.

A photovoltaic solar array is a set of solar photovoltaic modules electrically connected and mounted on supporting structures. A photovoltaic module, commonly called a “solar panel”, is a packaged, connected assembly of solar cells. The solar module can be used as a component of a larger photovoltaic system to generate and supply electricity in commercial and residential applications. Numerous technical problems exist in connection with mounting devices such as solar photovoltaic modules (“panels”) on surfaces that are, or may be, exposed to varying force vectors induced or caused by wind, snow, rain, and other elements of weather.

As can be seen, there is a need for an improved clamping system for clamping solar modules to panel support structures.

SUMMARY OF THE INVENTION

In one aspect of the present invention, a solar panel array is provided. The solar panel array may include a first support structure and a second support structure. The support structures may be secured to a surface. The present invention may further include a row spacer bar. The row spacer bar includes a first end and a second end. The first end is secured to the first support structure and the second end is secured to the second support structure. The present invention may further include at least one solar panel that is supported by the first and second support structures. The solar panel is secured to the row spacer bar by a clamp.

These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, description and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an embodiment of a solar panel array of the present invention;

FIG. 2 is a top view of an exemplary row spacer bar of the present invention;

FIG. 3 is a perspective view of the row spacer bar of FIG. 2 with clamps attached, removing the panels;

FIG. 4 is a perspective view of an exemplary middle clamp of the present invention;

FIG. 5 is a front view of the clamp of FIG. 4;

FIG. 6 is a perspective view of an exemplary end clamp of the present invention;

FIG. 7 is a front view of the clamp of FIG. 6;

FIG. 8 is a perspective view of an exemplary teethed clamp of the present invention;

FIG. 9 is a front view of the clamp of FIG. 8; and

FIG. 10 is a perspective view of an exemplary support structure.

DETAILED DESCRIPTION OF THE INVENTION

The following detailed description is of the best currently contemplated modes of carrying out exemplary embodiments of the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.

Broadly, an embodiment of the present invention provides a solar panel array that includes plurality of support structures. The support structures are secured to a surface and may support panels, such as solar modules. A row spacer bar may attach a pair of support structures together. A clamp may clamp the panels to the row spacer bar.

The present invention pertains generally to mounting energy-producing panels on surfaces. The new and useful low profile solid object mounting system of the present invention pertains to a system for securely, safely, yet quickly mounting objects, typically solar panels, onto horizontal or nearly horizontal surfaces by way of clamping the solar panels to north-south row spacer bars to resist movement from environmental factors, such as wind.

Referring to FIGS. 1 through 10, the present invention includes a solar panel array 10. The solar panel array 10 may include at least a first support structure 16 and a second support structure 16 that is attachable to a surface, such as a roof. The present invention may further include a row spacer bar 14 having a first end and a second end. The first end of the row spacer bar 14 may be secured to the first support structure 16 and the second end of the row spacer bar 14 may be secured to the second support structure 16. A solar panel 12 is supported by the first support structure 16 and the second support structure 16. Either one or multiple clamps 18 may clamp the solar panel 12 to the row spacer bar 14.

The support structures 16 of the present invention may include a first side 38, a second side 40 and a base 42 in between the first side 38 and second side 40. The first side 38 may include a top end and a bottom end. The bottom end of the first side 38 may be connected to the base 42. The top end of the first side 38 may form a channel 34. The channel 34 may face away from the second side 40. The second side 40 of the support structure 16 may include a top end and a bottom end. The bottom end of the second side 40 may be connected to the base 42. The top end of the second side 40 may form a support flange 36.

The support structures 16 of the present invention may be made of folded material to form a flat base 42, and a protruding first side 38 and second side 40. The support structures 16 may further include stiffeners to provide resistance to bending. In certain embodiments, the support flange 36 may be a flat bend or in certain embodiments may include a second channel. The support flange 36 of the second side 40 may be protruding towards the first side 38. The first side 38, second side 40, base 42, support flange 36 and/or the channel 34 may have mounting apertures 24 for mounting and attachments.

The sides 38, 40 may be vertical relative to the base 42, or set at an angle. In certain embodiments, the first side 38 may be shorter than the second side 40. However, the sides 38, 40 may be the same height or the second side 40 may be shorter than the first side 38. The height of the sides 38, 40 may be set so that the panels 12 may be suspended at a desired angle. The top ends of the sides 38, 40 may also be adjusted to suspend the panel 12 at a desired angle.

As mentioned above, the present invention may include a plurality of support structures 16, such as a first support structure 16 and a second support structure 16. The first and second support structures 16 may be mounted to a surface so that the channel 34 of the first support structure 16 is facing the support flange 36 of the second support structure 16. The first and second support structures 16 may be spaced apart by the row spacer bar 14 and/or a supplemental ballast pan. As mentioned above, the row spacer bar 14 may include a first end and a second end. The first end may be mounted within the channel 34 of the first support structure 16 and the second end may be mounted to the support flange 36 of the second support structure 16. Therefore, an appropriate amount of space is maintained between the first and second support structures 16.

The solar panel array 10 of the present invention may support panels 12. The panels 12 of the present invention may be a low profile solid or partially solid rectangular object, such as solar photovoltaic modules. However, the panel 12 is not limited to a solar photovoltaic module and may be any flat rigid structure with edges. The panel 12 may include a first edge and an opposing second edge.

The first edge may be placed within the channel 34 and the second edge may be supported by the support flange 36.

The row spacer bars 14 of the present invention may include a U-shape, L-shape, flat shape, rectangular tube shape, round tube shape or the like. As illustrated in FIG. 2, the row spacer bars 14 may include inner apertures 15 and outer apertures 17. Fasteners 30, 32 may run through the outer apertures 17 and into the mounting apertures 24 of the support structure 16, and thereby attaching the row spacer bar 14 to the support structures 16. Long fasteners 30 may run through the aperture 24 of the clamp 18 and the inner apertures 15 of the row spacer bars 14. The panels 12 may be arranged in between the clamps 18 and row spacer bar 14. Nuts 28 may be used to tighten the fasteners 30, 32. Therefore, the clamps 18 may be tightened against a top surface edge of the panels 12, and thereby secure the panels 12 to the row spacer bar 14. In certain embodiments, the nuts 28 may be pressure fitted nuts inserted into the apertures 15, 17. The fasteners 30, 32 of the present invention may include bolts, embedded threaded stud fasteners, and the like with the use of corresponding nuts 28.

The clamps 18 of the present invention may include any appropriate clamp 18 that may secure the panel 12 to the row spacer bars 14. As mentioned above, the clamps 18 of the present invention may include at least one aperture 24 running through the clamp 18 to receive a bolt 30, 32. In certain embodiments, the clamps 18 may include at least one spacer flange 20 protruding downward from the clamp 18, and thereby spacing multiple panels 12 apart from one another. For example, the clamps 18 may include two spacer flanges 20 extending downward. As illustrated in FIGS. 1, 8 and 9, the clamps 18 may also be in the form of end clamps 18. In such embodiments, the end clamps 18 may include a side flange 26 extending downward. The end clamps 18 may clamp sides of the panels 12 that are not adjacent to other panels 12. The side flange 26 may extend downward and may be secured against the row spacer bar 14. The side flange 26 may provide rotational resistance of the clamp 18, and thus fixedly securing the clamp 18 against the panel's 12 side edge.

As illustrated in FIG. 1, the solar panel array 10 may secure a plurality of panels 12, such as a first solar panel 12 and a second solar panel 12. In such embodiments, the present invention may include a first pair of support structures 16, a second pair of support structures 16, and a third pair of support structures 16. The first pair of support structures 16 may be connected by a first row spacer bar 14, the second pair of support structures 16 may be connected by a second row spacer bar 14, and the third pair of support structures 16 may be connected by a third row spacer bar 14. The first solar panel 12 may be supported by the first pair and the second pair of support structures 16, and the second solar panel 12 may be supported by the second pair and the third pair of support structures 16. The row spacer bars 14 may align with the sides of the panels 12. The first panel 12 may be clamped to the first row spacer 12 bar by a first end clamp 18, the first and second panels 12 may be clamped to the second row spacer bar 14 by a middle clamp 18, and the second panel 12 is clamped to the third row spacer bar 14 by a second end clamp 18. As illustrated in FIG. 3, more than one clamp 18 may be used to secure the panels 12 to a single row spacer bar 14.

The row spacer bars 14 of the present invention may secure the support structures 16 at a pre-determined distance north to south. The row spacer bars 14 may prevent the support structures 16 from moving apart North to South and keeps the lower channel 34 in place, ready to accept and secure a panel 12. Further, the clamping of the panels 12 to the row spacer bars 14 provides numerous advantages. The clamps 18 may act as an East-West spacer between solar panels 12. A less amount of clamps 18 may be used. For example, the southernmost row of the solar panel array 10 may include two clamps 18 for each row spacer bar 14 to resist rotation of the southern support structures 16. However, the northern solar panel array 10 rows may include a single clamp 18 used for each row spacer bar 14. Further, the present invention provides a location in which the clamps 18 may lock down the panels to the row spacer bars 14 in between the support structures 16. The location of the clamping point may be located at a distance from the panel's 12 corners to prevent a solar module frame from being deflected towards the glass too far in order to prevent glass compression in the solar panel and the possible resulting damage from occurring. The distance may be around 2.5 inches or greater.

In certain embodiments, the present invention may provide a grounding pathway for the solar panel array 10. Therefore, electrical grounding point may be connected to a single support structure 16 of a solar panel array 10 that may include a plurality of rows of panels 12. In such embodiments, teeth 22 may penetrate the solar panels 12. As illustrated in FIGS. 3, 6 and 7, the teeth 22 protrude downward from the clamp 18. However, a toothed washer may also be used. In such embodiments, the toothed washer may be secured in between the clamp 18 and the panel 12 or in between the row spacer bar 14 and the panel 12.

The electrical grounding point may be connected to at least one support structure 16. The plurality of teeth 22 provide an electrical ground path from the panels 12 to the clamp 18, through the long fasteners 30 and the at least one row spacer bar 14, and to the support structure 16. Therefore, electricity may travel from each panel 12 of the support panel array 10 to a single electrical grounding point.

It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims. 

What is claimed is:
 1. A solar panel array comprising: at least a first support structure and a second support structure configured to be secured to a surface; at least one row spacer bar comprising a first end and a second end, wherein the first end is secured to the first support structure and the second end is secured to the second support structure; at least one solar panel supported by the first support structure and the second support structure; and at least one clamp clamping the at least one solar panel to the at least one row spacer.
 2. The solar panel array of claim 1, further comprising a fastener running through the at least one clamp and through the at least one row spacer, thereby clamping the at least one solar panel to the at least one row spacer.
 3. The solar panel array of claim 1, wherein the at least one solar panel comprises a first solar panel and a second solar panel, wherein the at least one row spacer bar is disposed in between the first solar panel and the second solar panel.
 4. The solar panel array of claim 3, wherein the at least one clamp clamps the first solar panel and the second solar panel to the at least one row spacer.
 5. The solar panel array of claim 4, wherein the at least one clamp comprises at least one spacer flange protruding downward from the clamp, and thereby spacing the first solar panel and the second solar panel apart.
 6. The solar panel array of claim 3, further comprising a plurality of clamps disposed in between the first end and the second end of the at least one row spacer.
 7. The solar panel array of claim 3, further comprising a first pair of support structures, a second pair of support structures, and a third pair of support structures.
 8. The solar panel array of claim 7, wherein the first solar panel is support by the first pair and the second pair of support structures, and the second solar panel is supported by the second pair and the third pair of support structures.
 9. The solar panel array of claim 8, wherein the first pair of support structures is connected by a first row spacer bar, the second pair of support structures is connected by a second row spacer bar, and the third pair of support structures is connected by a third row spacer bar.
 10. The solar panel array of claim 9, wherein the first panel is clamped to the first row spacer bar by a first end clamp, the first and second panel are clamped to the second row spacer bar by a middle clamp, and the second panel is clamped to the third row spacer bar by a second end clamp.
 11. The solar panel array of claim 1, wherein the clamp comprises a plurality of teeth protruding downward and configured to electrically pierce the at least one solar panel.
 12. The solar panel array of claim 12, further comprising an electrical grounding point connected to at least one of the support structures, wherein the plurality of teeth provide a electrical ground path from the panels through the at least one row spacer bar, through at least one of the support structures and into the electrical grounding point.
 13. The solar panel array of claim 1, wherein each of the first and second support structure comprises a first side, a second side, and a base in between the first side and second side, wherein the first side comprises a top end and a bottom end, wherein the bottom end is connected to the base and the top end forms a channel, wherein the channel is substantially facing away from the second side, wherein the second side comprises a top end and a bottom end, wherein the bottom end is connected to the base and the top end forms a support flange.
 14. The solar panel array of claim 1, wherein the first support structure comprises a channel facing towards the second support structure, and the second support structure comprises a support flange, wherein the at least one solar panel comprises a first edge within the channel and a second edge supported by the support flange. 